Method of Manufacturing Heat Conductive Sheet, Heat Conductive Sheet, and Heat Dissipation Member

ABSTRACT

Provided is a method of manufacturing a heat conductive sheet with improved adhesion and heat conductivity. The method includes the steps of molding a heat conductive resin composition, which includes heat conductive fillers and a binder resin, into a predetermined shape and curing the heat conductive resin composition to obtain a molded product of the heat conductive resin composition, cutting the molded product into sheets to obtain a molded product sheet, and pressing the molded product sheet.

TECHNICAL FIELD

The present disclosure relates to a method of manufacturing a heat conductive sheet disposed between a heat generator, such as a semiconductor device, and a heat dissipater, such as a heat sink. The present disclosure also relates to such a heat conductive sheet and a heat dissipation member including the heat conductive sheet.

This application claims priority to and the benefit of Japanese Patent Application No. 2013-138460 filed on Jul. 1, 2013 and Japanese Patent Application No. 2014-123048 filed on Jun. 16, 2014, the entire contents of which are incorporated herein by reference.

BACKGROUND

Since semiconductor devices used in various electronic devices, such as a personal computer, and other devices generate heat when driven and the generated heat might build up to adversely affect actuation of the semiconductor devices and peripheral devices, various cooling methods are conventionally adopted. Examples of the cooling methods adopted in electronic elements, such as a semiconductor device, include a method of cooling air in a housing of the device by using a fan attached to the device, and a method of attaching a heat sink, such as a heat dissipation fin and a heat dissipation plate, to the semiconductor device to be cooled.

When a heat sink is attached to the semiconductor device for cooling, a heat conductive sheet is disposed between the semiconductor device and the heat sink to facilitate efficient dissipation of heat from the semiconductor device. As the heat conductive sheet, the one in which fillers, such as scale-like particles of boron nitride (BN), graphite, or the like, and heat conductive fillers of carbon fibers, or the like, are dispersed in a silicone resin. (Refer to Patent Literature 1.)

These heat conductive fillers have anisotropy of heat conduction. For example, when used as the heat conductive fillers, carbon fibers are known to exhibit a heat conductivity of about 600 W/m·K to 1200 W/m·K in a fiber direction, and boron nitride is also known to exhibit a heat conductivity of about 110 W/m·K in a surface direction and a heat conductivity of about 2 W/m·K in a direction perpendicular to the surface direction, thus having the anisotropy.

CITATION LIST Patent Literature PTL1: Japanese Patent Application Publication No. 2012-23335 SUMMARY Technical Problem

Here, the amount of heat dissipated by electronic elements, such as a CPU used in a personal computer, is increasing more than ever each year due to the increased speed and enhanced performance. In contrast, however, chip sizes of processors or the like are almost the same as or smaller than before due to development in a micro silicon circuit technology, and heat flux per unit area is increasing. Accordingly, to prevent troubles caused by the temperature rise or the like, there is a demand for a more effective way of dissipating heat from and cooling electronic elements, such as a CPU.

An increase in heat dissipation characteristics of a heat conductive sheet requires a decrease in heat resistance, which is an index indicating difficulty of heat conduction. To decrease heat resistance, it is effective to improve adhesion of the heat conductive sheet to an electronic element as a heat generator or to a heat sink or the like as a heat dissipater.

However, when the heat conductive fillers, such as carbon fibers, are exposed to a surface of the sheet, the conformity and adhesion to the heat generator and the heat dissipater are deteriorated, and heat resistance cannot be reduced satisfactorily. Although another method proposed is to sandwich the heat conductive sheet between the heat generator and the heat dissipater by using high load to sink the heat conductive fillers in the sheet, this method is not suitable when used for the heat generator requiring low load because, in this case, the heat conductive fillers do not sink, and heat resistance cannot be reduced.

Furthermore, the heat conductive fillers, such as carbon fibers, exposed to the surface of the sheet decrease weak stickiness (tackiness) of the surface of the sheet, and this inhibits provisional fixing to the heat generator and the heat dissipater. This poses the need for using an additional adhesive sheet or adhesive agent for provisional fixing at the time of mounting the heat conductive sheet between the heat generator and the heat dissipater. However, the use of such an adhesive sheet or adhesive agent complicates the mounting process.

In view of the above, the present disclosure is to provide a method of manufacturing a heat conductive sheet that itself is imparted with stickiness and therefore has improved adhesion to the heat generator and the heat dissipater and provides excellent heat conductivity and that may be fixed provisionally without the need for using an adhesive agent or the like and provides excellent mountability. The present disclosure is also to provide such a heat conductive sheet and a heat dissipation member including the heat conductive sheet.

Solution to Problem

One of aspects of the present disclosure for solving the above problem resides in a method of manufacturing a heat conductive sheet, including the steps of: molding a heat conductive resin composition, which includes heat conductive fillers and a binder resin, into a predetermined shape and curing the heat conductive resin composition to obtain a molded product of the heat conductive resin composition; cutting the molded product into sheets to obtain at least one molded product sheet; and pressing the molded product sheet.

Another aspect of the present disclosure resides in a heat conductive sheet, including: a sheet main body made of a cured heat conductive resin composition, which includes heat conductive fillers and a binder resin, wherein a surface of the sheet main body is coated with an uncured component of the binder resin.

Yet another aspect of the present disclosure resides in a heat dissipation member, including: a heat spreader configured to dissipate heat generated by an electronic element; and a heat conductive sheet disposed on the heat spreader and sandwiched between the heat spreader and the electronic element, wherein the heat conductive sheet includes a sheet main body made of a cured heat conductive resin composition, which includes heat conductive fillers and a binder resin, and an entire surface of the sheet main body is coated with an uncured component of the binder resin oozing from the sheet main body.

Advantageous Effect

According to the present disclosure, the surface of the sheet main body is coated with the uncured component of the binder resin, and the fillers exposed to the surface are also coated with the uncured component. Consequently, the surface of the sheet main body is imparted with weak stickiness (tackiness), resulting in improvement in conformity and adhesion to the heat generator, the heat dissipater, or the like to which the sheet is to be adhered, and this in turn results in a reduction in heat resistance.

Furthermore, with the surface of the sheet main body coated with the uncured component of the binder resin and imparted with weak stickiness, the present disclosure allows provisional fixing of the heat conductive sheet to the heat generator, the heat dissipater, or the like to which the sheet is to be adhered. Accordingly, the present disclosure is able to omit the need for using an additional adhesive agent and accordingly, simplify manufacturing processes and reduce cost.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings:

FIG. 1 is a sectional view illustrating a heat conductive sheet and a heat dissipation member to which the present disclosure is applied;

FIG. 2 is a perspective view of a state where a molded product sheet is pressed via a spacer; and

FIG. 3 is a perspective view illustrating a process of obtaining a large-sized heat conductive sheet by disposing a plurality of molded product sheets adjacent to each other and pressing the molded product sheets together.

DETAILED DESCRIPTION

Preferred embodiments of a method of manufacturing a heat conductive sheet, a heat conductive sheet, and a heat dissipation member to which the present disclosure is applied will be described in detail below with reference to the drawings. Needless to say, the present disclosure is not limited to the following embodiments, and various changes may be made without departing from the gist of the present invention. The drawings are merely schematically illustrated and proportions of dimensions and so forth may be different from actual ones. Specific dimensions and the like are to be determined in consideration of the description below. Furthermore, different drawings naturally include portions with different dimensional relations and ratios.

A heat conductive sheet 1 to which the present disclosure is applied dissipates heat generated by an electronic element 3, such as a semiconductor device. As illustrated in FIG. 1, the heat conductive sheet 1 is fixed to a main surface 2 a of a heat spreader 2 that opposes to the electronic element 3 to be sandwiched between the electronic element 3 and the heat spreader 2. The heat conductive sheet 1 is also sandwiched between the heat spreader 2 and the heat sink 5. The heat conductive sheet 1, together with the heat spreader 2, constitutes a heat dissipation member 4 that dissipates heat of the electronic element 3.

The heat spreader 2 is formed in, for example, a square plate shape and includes the main surface 2 a opposing to the electronic element 3 and a side wall 2 b extending from an outer circumference of the main surface 2 a. The heat conductive sheet 1 is disposed on the main surface 2 a of the heat spreader 2 that is surrounded by the side wall 2 b, and the heat sink 5 is disposed on another surface 2 c of the heat spreader 2 that opposes to the main surface 2 a via the heat conductive sheet 1. The heat spreader 2 with higher heat conductivity has lower heat resistance and absorbs heat of the electronic element 4, such as a semiconductor device, more effectively. Accordingly, copper and aluminum, which have excellent heat conductivity, may be used to form the heat spreader 2.

The electronic element 3 is, for example, a semiconductor package, such as a BGA, and mounted on a circuit board 6. An end surface of the side wall 2 b of the heat spreader 2 is also mounted on the circuit board 6 and thus, the side wall 2 b surrounds the electronic element 3 with a predetermined distance defined therebetween.

The heat conductive sheet 1 is adhered to the main surface 2 a of the heat spreader 2 to form the heat dissipation member 4 that absorbs heat generated by the semiconductor device 4 and dissipates the heat through the heat sink 5. The heat conductive sheet 1 may be adhered to the heat spreader 2 by using adhesive strength of the heat conductive sheet 1 itself which is described later or by using an adhesive agent as needed. As the adhesive agent, a known heat dissipation resin or heat dissipation adhesive film that serves to adhere the heat conductive sheet 1 to the heat spreader 2 and to conduct heat may be used.

[Heat Conductive Sheet 1]

The heat conductive sheet 1 includes a sheet main body 7 made of a cured heat conductive resin composition, which includes heat conductive fillers and a binder resin, and the entire surface of the sheet main body 7 is coated with an uncured component 8 of the binder resin oozing from the sheet main body.

The heat conductive sheet 1 may be manufactured by curing the heat conductive resin composition, which includes the heat conductive fillers and the binder resin, to obtain a resin molded product, cutting the obtained resin molded product into sheets to obtain a molded product sheet, and subsequently pressing the obtained molded product sheet. A description is given later in detail.

The heat conductive fillers included in the heat conductive sheet 1 serve to conduct heat from the electronic element 3 to the heat spreader 2 efficiently, and fibrous fillers may be preferably used. The fibrous fillers with an excessively small average diameter have an excessively large specific surface area, which in turn might lead to an excessively high viscosity of the resin composition in forming the heat conductive sheet 1, whereas those with an excessively large average diameter might pose difficulty in manufacturing the molded product. Accordingly, the average diameter of the fibrous fillers may be preferably in the range of 5 to 12 μm. The fibrous fillers may also have an average fiber length preferably in the range of 30 to 300 μm. An average fiber length of less than 30 μm tends to lead to an excessively large specific surface area and an excessively high viscosity of the heat conductive resin composition, and an average fiber length of more than 300 μm tends to hinder compression of the heat conductive sheet 1.

Detailed examples of the fibrous fillers preferably include, for example, carbon fibers, metal fibers (such as fibers of nickel and iron), glass fibers, and ceramic fibers (such as nonmetallic inorganic fibers, e.g., fibers of oxides such as aluminum oxide and silicon dioxide; nitrides such as boron nitride and aluminum nitride; borides such as aluminum boride; and carbides such as silicon carbide).

The fibrous fillers are selected according to the properties, such as mechanical properties, thermal properties, and electric properties, required for the heat conductive sheet 1. Especially, pitch-based carbon fibers or graphitized carbon fibers of polybenzazole may be preferably used due to their high elastic modulus, favorable heat conductivity, high electric conductivity, radio shielding properties, low thermal expansion, etc.

When the content of the fibrous fillers in the heat conductive sheet 1 is too small, the heat conductivity tends to become low, and when the content is too high, the viscosity tends to become high. Accordingly, the content of the fibrous fillers in the heat conductive sheet 1 is preferably in the range of 16 to 40 vol %.

In addition to the fibrous fillers, plate-like fillers, scale-like fillers, spherical fillers, or the like may also be used to an extent that does not impair the advantageous effect of the present disclosure. Especially, from the viewpoint of suppressing secondary aggregation of the fibrous fillers in the heat conductive resin composition, spherical fillers (preferably, spherical alumina or spherical aluminum nitride) having a diameter of 0.1 to 10 μm may be used in the amount of preferably 50 to 900 parts by mass based on 100 parts by mass of the fibrous fillers.

The binder resin is used to hold the fibrous fillers in the heat conductive sheet 1 and is selected according to the properties, such as mechanical strength, heat resistance, and electric properties, required for the heat conductive sheet 1. Such a binder resin may be selected from a thermoplastic resin, a thermoplastic elastomer, and a thermosetting resin.

Examples of the thermoplastic resin include: polyethylene, polypropylene, ethylene-α olefin copolymers such as ethylene-propylene copolymers, polymethylpentene, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, ethylene-vinyl acetate copolymers, polyvinyl alcohol, polyvinyl acetal, fluorine-based polymers such as polyvinylidene fluoride and polytetrafluoroethylene, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polystyrene, polyacrylonitrile, styrene-acrylonitrile copolymers, an acrylonitrile-butadiene-styrene copolymer (ABS) resin, a polyphenylene-ether copolymer (PPE) resin, a denatured PPE resin, aliphatic polyamides, aromatic polyamides, polyimide, polyamide-imide, polymethacrylic acid, polymethacrylates such as polymethyl methacrylate ester, polyacrylic acids, polycarbonate, polyphenylene sulfide, polysulfone, polyethersulfone, polyethernitrile, polyether ketone, polyketone, liquid crystal polymers, a silicone resin, and ionomers.

Examples of the thermoplastic elastomers include styrene-butadiene block copolymers and hydrogenated products thereof, styrene-isoprene block copolymers and hydrogenated products thereof, styrene-based thermoplastic elastomers, olefin-based thermoplastic elastomers, vinyl chloride-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

Examples of the thermosetting resin include cross-linked rubber, an epoxy resin, a phenolic resin, a polyimide resin, an unsaturated polyester resin, and a diallyl phthalate resin. Detailed examples of the cross-linked rubber include natural rubber, acrylic rubber, butadiene rubber, isoprene rubber, styrene-butadiene copolymer rubber, nitrile rubber, hydrogenated nitrile rubber, chloroprene rubber, ethylene-propylene copolymer rubber, chlorinated polyethylene rubber, chlorosulfonated polyethylene rubber, butyl rubber, halogenated butyl rubber, fluoro rubber, urethane rubber, and silicone rubber.

The heat conductive resin composition may be prepared by uniformly mixing the fibrous fillers and the binder resin, and as needed, various additives and a volatile solvent, by using a known method.

In the heat conductive sheet 1, as described later, the uncured component 8 of the binder resin oozes from the entire surface of the sheet main body 7 by pressing after the cutting into sheets, and the surface of the sheet main body 7 is coated with the uncured component 8. Accordingly, the fibrous fillers included in the heat conductive sheet 1 and exposed to the slice surface are coated with the uncured component of the binder resin, and the surface is imparted with weak stickiness (tackiness). Thus, the heat conductive sheet 1 has improved conformity and adhesion to surfaces of the electronic element 3 and the heat spreader 2, which in turn results in a reduction in heat resistance.

Furthermore, the surface of the sheet main body 7 coated with the uncured component 8 of the binder resin and imparted with weak stickiness allows adhesion of the heat conductive sheet 1 to the main surface 2 a of the heat spreader 2 or provisional fixing of the heat conductive sheet 1 to an upper surface 3 a of the electronic element 3. Thus, the heat conductive sheet 1 may omit the need for using an additional adhesive agent and accordingly, simplify manufacturing processes and reduce cost.

Herein, the heat conductive sheet 1 may achieve a desired weak stickiness (tackiness) by regulating a compounding ratio of a main ingredient and a curing agent of the binder resin which are included the heat conductive resin composition. For example, when a two-part liquid silicone resin of addition reaction type is used as the binder resin included in the heat conductive resin composition, the compounding ratio of the main ingredient and the curing agent is preferably set as follows:

Main ingredient:curing agent=35:65 to 65:35.

Regulating the compounding ratio in the above range allows the uncured component 8 of the binder resin to ooze out and coat the entire surface of the sheet main body 7 by the pressing while the sheet shape is maintained, and the entire heat conductive sheet 1 achieves an appropriate weak stickiness.

On the other hand, when the ratio of the main ingredient is less than the above compounding ratio, the heat conductive sheet 1 will be not flexible enough due to excessive curing of the binder resin, and moreover, the sheet main body 7 at least in part will not be imparted with even weak stickiness because the sheet main body 7 is not coated sufficiently with the uncured component 8 of the binder resin. When the ratio of the curing agent is less than the above compounding ratio, excessive stickiness will be imparted, leading to difficulty in maintaining the sheet shape, and operability will be deteriorated due to difficulty in cutting the molded product into sheets.

[Lightness L* in L*a*b Color System]

Object colors generally have three parameters of lightness (luminosity), hue (tone), and chroma (saturation). Precise color measurement and representation require a color system for numerically expressing the three parameters objectively. The L*a*b color system is an example of the color system. The L*a*b color system measurement may be conducted easily by using a measurement device, such as a commercial spectral colorimeter.

The L*a*b color system is a color system specified in, for example, JIS Z 8729 and JIS Z 8730, and representing colors transformed into a spherical color space. In the L*a*b color system, lightness is represented along a vertical axis (z-axis), hue is represented along a direction extending toward an outer circumference, and chroma is represented by a distance from a center axis.

The parameter L* represents a position on the vertical axis (z-axis) expressing lightness. The value of lightness L* is positive, and the smaller value indicates the lower lightness, that is to say, the darker color. In detail, the value of L* varies from 0, which corresponds to black, to 100, which corresponds to white.

Furthermore, in a section of the spherical color space taken horizontally at a position of L*=50, a positive direction of an x-axis represents increasing redness, a positive direction of a y-axis represents increasing yellowness, a negative direction of the x-axis represents increasing greenness, and a negative direction of the y-axis represents increasing blueness. The parameter a* represents a position on the x-axis and ranges from −60 to +60. The parameter b* represents a position on the y-axis and ranges from −60 to +60. In this way, the parameters a* and b* are positive or negative numbers representing chromaticity, and as the values are closer to 0 (zero), the colors become closer to black. Hue and chroma are represented by the values of a* and b*.

In the L*a*b color system, the larger lightness L* means increasing whiteness, and the smaller lightness L* means increasing blackness. Furthermore, in the L*a*b color system, the value of a* of less than −1 means increasing greenness, and the value of a* of −1 or more means increasing redness. Moreover, the value of b* of less than −1 means increasing blueness, and the value of b* of more than +1 means increasing yellowness.

The heat conductive sheet 1 includes the curable resin composition, the fibrous fillers, and heat conductive particles. As the volume % of the fibrous fillers is increased, the lightness L* of the surface of the heat conductive sheet 1 is decreased, and as the volume % of the heat conductive particles is increased, the lightness L* is increased. For example, suppose that the surface of a heat conductive sheet, in which the fibrous fillers are carbon fibers, and the heat conductive particles are particles of one or more of alumina, aluminum nitride, and aluminum hydroxide, including at least alumina, is observed. When the area of the carbon fibers is large and when a little white alumina or aluminum nitride is exposed to the surface, the lightness L* tends to be small, and when the area of the carbon fibers is small and when a lot of white alumina or aluminum nitride is exposed to the surface, the lightness L* tends to be large.

To achieve a heat conductive sheet having high heat conductivity, it is not sufficient simply to increase the content of the highly heat conductive fibrous fillers, and the heat conductive particles need to be added to maintain the shape of the heat conductive sheet. Furthermore, to reduce viscosity of the heat conductive resin composition at the time of extrusion, the compounding ratio of the fibrous fillers and the heat conductive particles need to be regulated.

The present inventors have discovered that setting the value of the lightness L* within a predetermined range allows achievement of favorable heat conductivity. That is to say, the heat conductive sheet 1 according to the present embodiment includes the curable resin composition, the fibrous fillers, and the heat conductive particles, and the L* value of the surface of the heat conductive sheet according to the L*a*b color system is in the range between 25 and 70. This helps achieve favorable heat conductivity in a thickness direction of the heat conductive sheet 1. Even when the surface of the sheet has a spotted or a striped pattern, there is no problem if only the L* value falls within the above range. When the surface of the sheet has a spotted or a striped pattern, the fibrous fillers are not orientated to a certain direction but orientated randomly in the thickness direction. The random orientation increases entanglement of the fibrous fillers and points of contact between heat conductive particles, and heat conductivity becomes higher than when the fibrous fillers are orientated to a certain direction. During the process of extruding the heat conductive resin composition into a hollow die, the heat conductive resin composition is extruded through a slit and closely contact within the hollow die. In this process, light and dark irregularities appear on the surface. The L* value of the surface of the heat conductive sheet 1 according to the L*a*b color system may be regulated by adjusting mixing time and stirring rate. As the mixing time is increased and as the stirring rate is increased, the fibrous fillers become small, and the L* value is reduced. On the other hand, as the mixing time is reduced and as the stirring rate is reduced, the fibrous fillers do not become small, and the L* value is increased. Furthermore, when the surface of the sheet is glossy, the L* value tends to be increased. Glossiness of the surface of the sheet may be adjusted by mixing oil and varying an A/B ratio of silicone.

[Manufacturing Processes of Heat Conductive Sheet]

The heat conductive sheet 1 of the present disclosure may be manufactured by a manufacturing method including the following processes (A) to (C). Each of these processes are described in detail below.

<Process A>

First, the fibrous fillers are dispersed in the binder resin to prepare a heat conductive resin composition to be used for manufacturing the heat conductive sheet 1. The preparation may be conducted by uniformly mixing the fibrous fillers and the binder resin, and as needed, various additives and a volatile solvent, by using any known mixing method.

<Process B>

Next, a block of a molded product is formed from the prepared heat conductive resin composition by an extrusion molding method or a metal molding method.

No particular limitation is imposed on the extrusion molding method and metal molding method to be used, and an appropriate method may be selected from various known extrusion molding methods and metal molding methods according to the viscosity of the heat conductive resin composition, the properties required for the heat conductive sheet 1, and so forth.

When the heat conductive resin composition is extruded from a die used in the extrusion molding method or when the heat conductive resin composition is injected into a mold used in the metal molding method, the binder resin flows, and some portions of the fibrous fillers are orientated in the direction of the flow, but the majority of the fibrous fillers are orientated randomly.

When a slit is attached to a tip of the die, the fibrous fillers are more likely to be orientated in a middle portion of the extruded block of the molded product with respect to a widthwise direction thereof. On the other hand, the fibrous fillers are more likely to be orientated randomly in a peripheral portion of the block of the molded product with respect to the widthwise direction thereof under the influence of a wall of the slit.

The size and shape of the block of the molded product may be determined according to the required size of the heat conductive sheet 1. For example, the block of the molded product may be a cuboid having a cross section with a vertical dimension of 0.5 to 15 cm and a horizontal dimension of 0.5 to 15 cm. The length of the cuboid may be determined as needed.

<Process C>

Next, the formed block of the molded product is sliced into sheets. Thus, a molded product sheet, from which the sheet main body 7 is to be formed, is obtained. The fibrous fillers are exposed to the surface (the slice surface) of the sheet resulting from the slicing. No particular limitation is imposed on the slicing method, and an appropriate machine may be selected from known slicing machines (preferably, an ultrasonic cutter or a plane) according to the size and mechanical strength of the block of the molded product. When an extrusion molding method is used as the molding method, some fibrous fillers are orientated in the direction of extrusion. Accordingly, the direction in which the block of the molded product is to be sliced is preferably from 60 to 120 degrees and more preferably from 70 to 100 degrees with respect to the direction of extrusion. The direction is most preferably 90 degrees (orthogonal to the direction of extrusion).

No particular limitation is imposed on the slice thickness, and any appropriate slice thickness may be selected according to, for example, the intended purpose of the heat conductive sheet 1.

<Process D>

Subsequently, the slice surface of the obtained molded product sheet is pressed. The pressing may be conducted by, for example, a pair of press machines including a flat plate and a flat press head. A pinch roll may also be used.

As a result, from the molded product sheet, the heat conductive sheet 1, in which the uncured component 8 of the binder resin oozes from the sheet main body 7 to coat the entire surface of the sheet main body 7, is obtained. In the heat conductive sheet 1, the fibrous fillers exposed to the slice surface are coated with the uncured component 8 of the binder resin, and the surface is imparted with weak stickiness (tackiness). Accordingly, the heat conductive sheet 1 has improved conformity and adhesion to surfaces of the electronic element 3 and the heat spreader 2, which in turn results in a reduction in heat resistance.

Furthermore, since the surface of the sheet main body 7 of the heat conductive sheet 1 is coated with the uncured component 8 of the binder resin, and the surface of the heat conductive sheet 1 is imparted with weak stickiness, the heat conductive sheet 1 may be provisionally fixed to the main surface 2 a of the heat spreader 2 or the upper surface 3 a of the electronic element 3. Thus, the heat conductive sheet 1 omits the need for using an additional adhesive agent and accordingly, simplifies manufacturing processes and reduces cost.

Even when the weak stickiness of the surface of the heat conductive sheet 1 is lost during handling, pressing the heat conductive sheet 1 allows the uncured component 8 of the binder resin to ooze from the sheet main body 7 again to coat the surface. Accordingly, even when adhered to the heat spreader 2 at a wrong position or provisionally fixed to the electronic element 3 at a wrong position, the heat conductive sheet 1 may be repaired.

Furthermore, in the heat conductive sheet 1, the uncured component 8 of the binder resin oozes from the entire surface of the sheet main body 7 to coat not only front and back surfaces but also side surfaces of the sheet main body 7. The uncured component 8 of the binder resin has insulating properties, and the heat conductive sheet 1 is imparted on side surfaces thereof with insulating properties. Accordingly, even when the heat conductive sheet 1 sandwiched between the electronic element 3 and the heat spreader 2 bulges to the periphery and come into contact with a conductive member disposed on the periphery, short circuit between the semiconductor device or the heat sink and the conductive member is prevented by way of the heat conductive sheet 1.

The heat conductive sheet 1 is compressed in the thickness direction as a result of pressing, and consequently, the fibrous fillers contact with each other more frequently. This reduces heat resistance of the heat conductive sheet 1. Furthermore, the surface of the heat conductive sheet 1 is smoothened as a result of pressing.

Pressing force is preferably in the range of 0.0098 to 9.8 MPa and more preferably in the range of 0.049 to 9.3 MPa; when pressing force is too low, heat resistance tends to remain unchanged from that of an unpressed sheet, and when pressing force is too high, the sheet tends to be stretched.

As illustrated in FIG. 2, the molded product sheet 11 may be pressed with a spacer 10 resting on a surface opposing a press head, and thus, the heat conductive sheet 1 having a predetermined sheet thickness corresponding to the height of the spacer 10 is achieved.

In the heat conductive sheet 1, as a result of pressing, the uncured component 8 of the binder resin included in the sheet main body 7 oozes out until the uncured component 8 coats the entire surface of the sheet. The pressing time period may be set long enough to allow the uncured component of the binder resin to ooze out to coat the entire surface of the sheet main body 7 as appropriate in accordance with the compounding ratio between the binder resin component and the curing agent component included in the binder resin, pressing force, an area of the sheet, and so forth.

To promote the oozing of the uncured component 8 of the binder resin and the effect of coating the surface of the sheet main body 7, the pressing process may be conducted while heating by using a pressing head provided with a heater. To enhance the effect, the heating temperature is preferably set to be a glass transition temperature of the binder resin or higher. This helps reduce the pressing time period.

Furthermore, as illustrated in FIG. 3, a plurality of (for example, 4 pieces of) molded product sheets 11 may be disposed adjacently and heat pressed together by a press head 12 without using the spacer 10. By doing so, the large-sized heat conductive sheet 1 in which the integrated molded product sheets 11 are integrated is manufactured. In this case, the molded product sheets 11 each have a substantially rectangular shape having the same dimension and thickness and are preferably disposed adjacent to each other at an equal interval with one side of a molded product sheet 11 aligned with one side of the adjacent molded product sheet 11. In this way, the seamless and flat heat conductive sheet 1 having a uniform thickness is manufactured. In the large-sized heat conductive sheet 1 in which the molded product sheets 11 are integrated, the entire surface of the sheet main body 7 is coated with the uncured component of the binder resin oozing out as a result of pressing.

EXAMPLES First Examples

The following describes the first examples (Examples 1 to 7) and the first comparative examples (Comparative Examples 1 to 4). For the first examples and the first comparative examples, heat conductive sheet samples were prepared by varying the compounding ratio between the binder component and the curing agent component included in the heat conductive resin composition. For each sample, peel force (N/cm) of a PET film and heat resistance (K·cm²/W) were measured and evaluated, and workability in cutting into sheets, peeling from the release film, and adhesion.

Example 1

A silicone resin composition (heat conductive resin composition) of Example 1 was prepared by dispersing, in a two-part liquid silicone resin of addition reaction type, 20 vol % of alumina particles (as heat conductive particles manufactured by Denki Kagaku Kogyo Kabushiki Kaisha) having an average particle diameter of 4 μm and treated with a silane coupling agent, and 22 vol % of pitch-based carbon fibers (as heat conductive fibers manufactured by Nippon Graphite Fiber Co., Ltd.) having an average fiber length of 150 μm and an average fiber diameter of 9 μm, and 24 vol % of aluminum nitride (as heat conductive particles manufactured by Tokuyama Corporation) having an average particle diameter of 1 μm and treated with a silane coupling agent. The two-part liquid silicone resin of addition reaction type included 35 mass % of a silicone A liquid and 65 mass % of a silicone B liquid mixed together. The prepared silicone resin composition was extruded into a cuboid mold (20 mm×20 mm) having an inner wall applied with a PET film treated with a release coating to mold a silicone molded product. The obtained silicone molded product was cured in an oven for 6 hours at 100° C. to form a silicone cured product. The formed silicone cured product was heated in an oven for 1 hour at 100° C. and subsequently, cut by an ultrasonic cutter to obtain a molded product sheet having a thickness of 1.53 mm. A slicing rate of the ultrasonic cutter was 50 mm per second. Supersonic vibration applied to the ultrasonic cutter had an oscillation frequency of 20.5 kHz and an amplitude of 60 μm.

The obtained molded product sheet was sandwiched between PET films treated with a release coating and subsequently, pressed via a spacer having a thickness of 1.49 mm, and thus, the heat conductive sheet sample having a thickness of 1.50 mm was prepared. The pressing conditions were 80° C., 2.45 MPa and 3 minutes.

Example 2

A heat conductive sheet sample of Example 2 was prepared under the same conditions as those of Example 1, except for that the two-part liquid silicone resin of addition reaction type included 40 mass % of the silicone A liquid and 60 mass % of the silicone B liquid mixed together.

Example 3

A heat conductive sheet sample of Example 3 was prepared under the same conditions as those of Example 1, except for that the two-part liquid silicone resin of addition reaction type included 45 mass % of the silicone A liquid and 55 mass % of the silicone B liquid mixed together.

Example 4

A heat conductive sheet sample of Example 4 was prepared under the same conditions as those of Example 1, except for that the two-part liquid silicone resin of addition reaction type included 50 mass % of the silicone A liquid and 50 mass % of the silicone B liquid mixed together.

Example 5

A heat conductive sheet sample of Example 5 was prepared under the same conditions as those of Example 1, except for that the two-part liquid silicone resin of addition reaction type included 55 mass % of the silicone A liquid and 45 mass % of the silicone B liquid mixed together.

Example 6

A heat conductive sheet sample of Example 6 was prepared under the same conditions as those of Example 1, except for that the two-part liquid silicone resin of addition reaction type included 60 mass % of the silicone A liquid and 40 mass % of the silicone B liquid mixed together.

Example 7

A heat conductive sheet sample of Example 7 was prepared under the same conditions as those of Example 1, except for that the two-part liquid silicone resin of addition reaction type included 65 mass % of the silicone A liquid and 35 mass % of the silicone B liquid mixed together.

First Comparative Examples Comparative Example 1

A heat conductive sheet sample of Comparative Example 1 was prepared under the same conditions as those of Example 1, except for that the two-part liquid silicone resin of addition reaction type included 25 mass % of the silicone A liquid and 75 mass % of the silicone B liquid mixed together.

Comparative Example 2

A heat conductive sheet sample of Comparative Example 2 was prepared under the same conditions as those of Example 1, except for that the two-part liquid silicone resin of addition reaction type included 30 mass % of the silicone A liquid and 70 mass % of the silicone B liquid mixed together.

Comparative Example 3

A heat conductive sheet sample of Comparative Example 3 was prepared under the same conditions as those of Example 1, except for that the two-part liquid silicone resin of addition reaction type included 70 mass % of the silicone A liquid and 30 mass % of the silicone B liquid mixed together.

Comparative Example 4

A heat conductive sheet sample of Comparative Example 4 was prepared under the same conditions as those of Example 1, except for that the two-part liquid silicone resin of addition reaction type included 75 mass % of the silicone A liquid and 25 mass % of the silicone B liquid mixed together

[Measurement of Peel Force]

The heat conductive sheet samples of Examples 1 to 7 and Comparative Examples 1 to 4 were peeled from the PET film treated with a release coating and then sandwiched by PET untreated with a release coating. Subsequently, each heat conductive sheet sample was pressed via a spacer having a thickness of 1.49 mm for 3 minutes at 80° C. and 2.45 MPa and cooled to a normal temperature. After that, an end of the PET film was peeled by hand and clamped by a testing machine and then, the PET film was pulled upward at an angle of 90° at a rate of 50 mm/min to measure load. Thus, weak stickiness (tackiness) of each heat conductive sheet sample was evaluated. The peel force (load) of each sample was measured with a predetermined tolerance. As for evaluation criteria, the peel force was evaluated as optimal when the peel force oscillated in the range of 0.02 to 0.15 (N/cm), as good when the peel force oscillated in the range of 0.02 to 0.04 (N/cm) and 0.15 to 0.25 (N/cm), as fair when the peel force oscillated in the range of 0 to 0.02 (N/cm) and 0.20 to 0.30 (N/cm), and as poor when the peel force was 0 (N/cm).

[Measurement of Heat Resistance]

The heat resistance of each of the heat conductive sheet samples of Examples 1 to 7 and Comparative Examples 1 to 4 was also measured by a method in compliance with ASTM-D5470 at loads of 0.5 kgf/cm² and 7.5 kgf/cm². As for evaluation criteria, the heat resistance at a load of 0.5 kgf/cm² was evaluated as optimal when the heat resistance does not exceed approximately 0.65 (K·cm²/W), as good when the heat resistance is in the range of 0.65 to 0.847 (K·cm²/W), as fair when the heat resistance is in the range of 0.847 to 0.87 (K·cm²/W), and as poor when the heat resistance is 0.87 (K·cm²/W) or more. The heat resistance at a load of 7.5 kgf/cm² may be evaluated similarly to the case of a load of 0.5 kgf/cm², although not evaluated specifically.

[Evaluation of Workability]

Workability in cutting into sheets, peeling from the release film, and adhesion of each of the heat conductive sheet samples of Examples 1 to 7 and Comparative Examples 1 to 4 was also evaluated. As for evaluation criteria, workability was evaluated as good when a molded product sheet having a thickness of 1.53 mm was cut out of the silicone cured product by using an ultrasonic cutter, the sheet main body was not deformed at the time of peeling the PET film from the heat conductive sheet sample, and adhesion was performed with a predetermined degree of tackiness, and workability was evaluated as poor when the cutting, peeling, and adhesion operations were not performed smoothly.

TABLE 1 Exam- Exam- Exam- Exam- Exam- Exam- Exam- Comparative Comparative Comparative Comparative ple 1 ple 2 ple 3 ple 4 ple 5 ple 6 ple 7 Example 1 Example 2 Example 3 Example 4 Silicone A [%] 35 40 45 50 55 60 65 25 30 70 75 Silicone B [%] 65 60 55 50 45 40 35 75 70 30 25 PET peel force 0 to 0.02 to 0.02 to 0.02 to 0.05 to 0.05 to 0.10 to 0 0 0.15 to 0.20 to [N/cm] 0.02 0.04 0.04 0.05 0.10 0.10 0.15 0.25 0.30 Weak stickiness Fair Good Good Optimal Optimal Optimal Optimal Poor Poor Good Fair Hardness of 25 to 20 to 15 to 15 to 10 to 10 to 10 to 35 to 30 to 5 to 2 to composition 35 30 25 25 20 20 20 45 40 15 12 [N/cm²] Heat resistance Good Good Good Optimal Optimal Optimal Good Poor Fair Good Fair Workability Good Good Good Good Good Good Good Good Good Poor Poor Heat resistance 0.817 0.732 0.685 0.618 0.525 0.641 0.813 0.876 0.847 0.847 0.878 [K · cm²/W] at load of 0.5 kgf/cm² Heat resistance 0.323 0.298 0.256 0.221 0.181 0.170 0.203 0.356 0.378 0.307 0.312 [K · cm²/W] at load of 7.5 kgf/cm²

As illustrated in Table 1, regarding the heat conductive sheet samples of Examples 1 to 7, the peeling force (N/cm) of the PET film oscillated in the range of 0 to 0.25, and it can be seen that appropriate weak stickiness (tackiness) is imparted. In this regard, the peeling force of Example 1 encompasses 0 (N/cm) because the value obtained when the PET film starts to peel is measured to be lower than an actual peeling force.

Thus, in each of the heat conductive sheet samples of Examples 1 to 7, the uncured component of the silicone liquid oozed out of the entire surface of the sheet to coat the entire surface, and thereby the appropriate stickiness is imparted. Accordingly, the heat conductive sheet samples of Examples 1 to 7 had improved conformity and adhesion to surfaces of objects to which the conductive sheet samples were to be adhered and therefore, reduced heat resistance.

Since the surfaces of the heat conductive sheet samples of Examples 1 to 7 are each coated with the uncured component of the binder resin, and the surface of the heat conductive sheet sample is imparted with weak stickiness, the heat conductive sheet sample may be provisionally fixed. This omits the need for using an additional adhesive agent and accordingly, simplifies manufacturing processes and reduces cost.

In contrast, regarding each of the heat conductive sheet samples of Comparative Example 1 and 2, in which the compounding ratio of the silicone A liquid was as low as 30% or less, the uncured component did not remain sufficiently, and even after pressing, the entire surface was not coated with the uncured component, and weak stickiness was not imparted. Furthermore, the heat conductive sheet samples of Comparative Examples 1 and 2 lacked flexibility and included the carbon fibers exposed to the surface, and therefore, had poor conformity and adhesion to surfaces of objects to which the heat conductive sheet sample is to be adhered. As a result, the heat resistance was increased.

Regarding each of the heat conductive sheet samples of Comparative Examples 3 and 4, in which the compounding ratio of the silicone A liquid was as high as 70% or more, the sheet main body was not hard enough to maintain the shape. When the PET film was attempted to be peeled, the sheet shape cannot be maintained, and handling is difficult. Furthermore, in the heat conductive sheet samples of Comparative Examples 3 and 4, the carbon fibers were inclined in the surface direction by the pressing, and the heat resistance was increased. Moreover, the heat conductive sheet samples of Comparative Examples 3 and 4 lacked hardness of the silicone cured product, and the process of cutting into thin sheets was difficult.

Second Examples

The following describes the second examples (Examples 8 to 14) and the second comparative examples (Comparative Examples 5 to 8). For the second examples and the second comparative examples, similarly to the first examples, the compounding ratio between the binder component and the curing agent component included in the heat conductive resin composition was varied, and for each of thus prepared heat conductive sheets, the compression stress and the residual stress with or without the pressing and the content of the uncured component in the heat conductive resin composition were measured.

Example 8

A silicone resin composition (as heat conductive resin composition) of Example 8 was prepared by dispersing, in a two-part liquid silicone resin of addition reaction type, 20 vol % of alumina particles (as heat conductive particles manufactured by Denki Kagaku Kogyo Kabushiki Kaisha) having an average particle diameter of 4 μm and treated with a silane coupling agent, and 22 vol % of pitch-based carbon fibers (as heat conductive fibers manufactured by Nippon Graphite Fiber Co., Ltd.) having an average fiber length of 150 μm and an average fiber diameter of 9 μm, and 24 vol % of aluminum nitride (as heat conductive particles manufactured by Tokuyama Corporation) having an average particle diameter of 1 μm and treated with a silane coupling agent. The two-part liquid silicone resin of addition reaction type included 35 mass % of the silicone A liquid and 65 mass % of the silicone B liquid mixed together. The prepared silicone resin composition was extruded into a cuboid mold (50 mm×50 mm) having an inner wall applied with a PET film treated with a release coating to mold a silicone molded product. The obtained silicone molded product was cured in an oven for 6 hours at 100° C. to form a silicone cured product. The formed silicone cured product was heated in an oven for 1 hour at 100° C. and subsequently, cut by an ultrasonic cutter. The cut silicone cured product was further cut into 25 mm×25 mm pieces to obtain a molded product sheet having a thickness of 3.03 mm. The obtained molded product sheet is called the molded product sheet before pressing. Supersonic vibration applied to the ultrasonic cutter had an oscillation frequency of 20.5 kHz and an amplitude of 60 μm. The slicing rate of the ultrasonic cutter was 50 mm per second.

The obtained molded product sheet before pressing was sandwiched between PET films treated with a release coating and subsequently, pressed without using a spacer, and thus, a molded product sheet (heat conductive sheet) after pressing having a thickness of 2.95 mm was prepared. The pressing conditions were 100° C., 10 seconds, and 0.1 MPa. The content of the uncured component in the molded product sheet after pressing was 1.0%.

Example 9

Molded product sheets before and after pressing of Example 9 were prepared under the same conditions as those of Example 8, except for that the two-part liquid silicone resin of addition reaction type included 40 mass % of the silicone A liquid and 60 mass % of the silicone B liquid mixed together. The molded product sheet before pressing had a thickness of 3.01 mm, and the molded product sheet after pressing had a thickness of 2.96 mm. The content of the uncured component in the molded product sheet after pressing was 1.1%.

Example 10

Molded product sheets before and after pressing of Example 10 were prepared under the same conditions as those of Example 8, except for that the two-part liquid silicone resin of addition reaction type included 45 mass % of the silicone A liquid and 55 mass % of the silicone B liquid mixed together. The molded product sheet before pressing had a thickness of 3.05 mm, and the molded product sheet after pressing had a thickness of 2.98 mm. The content of the uncured component in the molded product sheet after pressing was 1.3%.

Example 11

Molded product sheets before and after pressing of Example 11 were prepared under the same conditions as those of Example 8, except for that the two-part liquid silicone resin of addition reaction type included 50 mass % of the silicone A liquid and 50 mass % of the silicone B liquid mixed together. The molded product sheet before pressing had a thickness of 3.02 mm, and the molded product sheet after pressing had a thickness of 2.96 mm. The content of the uncured component in the molded product sheet after pressing was 1.5%.

Example 12

Molded product sheets before and after pressing of Example 12 were prepared under the same conditions as those of Example 8, except for that the two-part liquid silicone resin of addition reaction type included 55 mass % of the silicone A liquid and 45 mass % of the silicone B liquid mixed together. The molded product sheet before pressing had a thickness of 3.01 mm, and the molded product sheet after pressing had a thickness of 2.97 mm. The content of the uncured component in the molded product sheet after pressing was 3.4%.

Example 13

Molded product sheets before and after pressing of Example 13 were prepared under the same conditions as those of Example 8, except for that the two-part liquid silicone resin of addition reaction type included 60 mass % of the silicone A liquid and 40 mass % of the silicone B liquid mixed together. The molded product sheet before pressing had a thickness of 3.03 mm, and the molded product sheet after pressing had a thickness of 2.90 mm. The content of the uncured component in the molded product sheet after pressing was 4.5%.

Example 14

Molded product sheets before and after pressing of Example 14 were prepared under the same conditions as those of Example 8, except for that the two-part liquid silicone resin of addition reaction type included 65 mass % of the silicone A liquid and 35 mass % of the silicone B liquid mixed together. The molded product sheet before pressing had a thickness of 3.00 mm, and the molded product sheet after pressing had a thickness of 2.88 mm. The content of the uncured component in the molded product sheet after pressing was 5.0%.

Second Comparative Examples Comparative Example 5

Molded product sheets before and after pressing of Comparative Example 5 were was prepared under the same conditions as those of Example 8, except for that the two-part liquid silicone resin of addition reaction type included 25 mass % of the silicone A liquid and 75 mass % of the silicone B liquid mixed together. The molded product sheet before pressing had a thickness of 3.03 mm, and the molded product sheet after pressing had a thickness of 3.01 mm. The content of the uncured component in the molded product sheet after pressing was 0.5%.

Comparative Example 6

Molded product sheets before and after pressing of Comparative Example 6 were prepared under the same conditions as those of Example 8, except for that the two-part liquid silicone resin of addition reaction type included 30 mass % of the silicone A liquid and 70 mass % of the silicone B liquid mixed together. The molded product sheet before pressing had a thickness of 3.02 mm, and the molded product sheet after pressing had a thickness of 3.00 mm. The content of the uncured component in the molded product sheet after pressing was 0.65%.

Comparative Example 7

Molded product sheets before and after pressing of Comparative Example 7 were prepared under the same conditions as those of Example 8, except for that the two-part liquid silicone resin of addition reaction type included 70 mass % of the silicone A liquid and 30 mass % of the silicone B liquid mixed together. The molded product sheet before pressing had a thickness of 3.08 mm, and the molded product sheet after pressing had a thickness of 2.92 mm. The content of the uncured component in the molded product sheet after pressing was 5.5%.

Comparative Example 8

Molded product sheets before and after pressing of Comparative Example 8 were prepared under the same conditions as those of Example 8, except for that the two-part liquid silicone resin of addition reaction type included 75 mass % of the silicone A liquid and 25 mass % of the silicone B liquid mixed together. The molded product sheet before pressing had a thickness of 3.02 mm, and the molded product sheet after pressing had a thickness of 2.87 mm. The content of the uncured component in the molded product sheet after pressing was 6.0%.

[Measurement of Compression Stress]

By using a tensile and compression testing machine (Tensilon RTG-1225 manufactured by A & D Company, Limited), the maximum compression stress of each of the molded product sheets before and after pressing of Examples 8 to 14 and Comparative Example 5 to 8 when compressed 40% at a compression rate of 25.4 mm/min was measured.

[Measurement of Residual Stress]

The molded product sheets before and after pressing of Examples 8 to 14 and Comparative Example 5 to 8 whose maximum compression stresses were measured were retained with the 40% compression for 10 minutes, and compression stresses were measured when 10 minutes elapsed.

[Measurement of Content of Uncured Component]

The molded product sheets before and after pressing of Examples 8 to 14 and Comparative Example 5 to 8 were punched into 20 mmφ pieces, and a piece of filter paper (No. 1 manufactured by Advantec Toyo Co., Ltd.) was disposed over and under each sheet, and the sheet was left standing in an oven at a temperature of 125° C. for 24 hours with a 9.42 kg weight placed thereon to let the uncured component adsorb to the filter paper. After the sheet was moved back to a room temperature, the filter paper was removed, and the content of the uncured component was obtained by calculating a rate of change in mass by measuring the mass of the molded product sheet.

[Measurement of Heat Resistance]

The heat resistance of each of the heat conductive sheet samples of Examples 8 to 14 and Comparative Examples 5 to 8 was measured by a method in compliance with ASTM-D5470 at loads of 0.5 kgf/cm² and 7.5 kgf/cm².

TABLE 2 Exam- Exam- Exam- Exam- Exam- Exam- Exam- Comparative Comparative Comparative Comparative ple 8 ple 9 ple 10 ple 11 ple 12 ple 13 ple 14 Example 5 Example 6 Example 7 Example 8 Silicone A [%] 35 40 45 50 55 60 65 25 30 70 75 Silicone B [%] 65 60 55 50 45 40 35 75 70 30 25 Maximum compression 1350 1200 1150 990 940 790 690 1400 1375 600 570 stress [N] of molded product sheet before pressing Residual stress [N] of 570 450 300 240 175 130 110 650 600 90 80 molded product sheet before pressing Thickness [mm] of 3.03 3.01 3.05 3.02 3.01 3.03 3.00 3.03 3.02 3.08 3.02 molded product sheet before pressing Maximum compression 1120 1080 900 770 710 570 540 1200 1190 480 460 stress [N] of molded product sheet after pressing Residual stress [N] of 570 450 295 235 170 120 100 645 600 85 80 molded product sheet after pressing Thickness [mm] of 2.95 2.96 2.98 2.96 2.97 2.90 2.88 3.01 3.00 2.92 2.87 molded product sheet after pressing Content [%] of 1.0 1.1 1.3 1.5 3.4 4.5 5.0 0.5 0.7 5.5 6.0 uncured component of molded product sheet before pressing

The molded product sheets after pressing were expected to be harder due to the higher densities than the molded product sheets before pressing. However, it has been found that the maximum compression stresses of the molded product sheets after pressing are less than those of the molded product sheets before pressing. Excessive maximum compression stress and residual stress mean that a greater load is applied to the board during mounting, and therefore, Examples 8 to 14, whose maximum compression stresses and residual stresses are small, are preferable.

Furthermore, in the molded product sheets after pressing of the heat conductive sheet samples of Examples 8 to 14, the contents of the uncured component were in the range between 1% and 5%. Although too much content of the uncured component might lead to a contact surface between a heat source or a heat dissipater and the sheet being smeared with oil, the uncured component in the range between 1% and 5% will not be an obstacle for use as the heat conductive sheet. Too little content of the uncured component might lead to an increase in heat resistance due to contact failure with the heat source and the dissipater, and therefore, the content of the uncured component is preferably in the range of Examples 8 to 14.

In contrast, regarding each of the heat conductive sheet samples of Comparative Examples 5 and 6, in which the compounding ratio of the silicone A liquid was as low as 30% or less, the uncured component did not remain sufficiently in the molded product sheet after pressing, and even after pressing, the entire surface was not coated with the uncured component, and weak stickiness was not imparted. Furthermore, the heat conductive sheet samples of Comparative Examples 5 and 6 each lacked flexibility and included the carbon fibers exposed to the surface, and therefore, had poor conformity and adhesion to surfaces of objects to which the heat conductive sheet sample is to be adhered. As a result, the heat resistance was increased compared with Examples 8 to 14.

Regarding each of the heat conductive sheet samples of Comparative Examples 7 and 8, in which the compounding ratio of the silicone A liquid was as high as 70% or more, the sheet main body was not hard enough to maintain the shape. When the PET film was attempted to be peeled, the sheet shape cannot be maintained, and handling is difficult. Furthermore, the heat conductive sheet samples of Comparative Examples 7 and 8 lacked hardness of the silicone cured product, and the process of cutting into thin sheets was difficult.

Moreover, in the heat conductive sheet samples of Comparative Examples 7 and 8, the content of the uncured component in the molded product sheets after pressing was more than 5%. Since the content of the uncured component in the heat conductive sheet samples of Comparative Examples 7 and 8 are greater than those of Examples 8 to 14, there is a risk that the contact surface between the heat source or the heat dissipater and the sheet might be smeared with oil.

REFERENCE SIGNS LIST

-   -   1 heat conductive sheet     -   2 heat spreader     -   2 a main surface     -   3 electronic element     -   3 a upper surface     -   4 heat dissipation member     -   5 heat sink     -   6 circuit board     -   10 spacer 

1. A method of manufacturing a heat conductive sheet, comprising the steps of: molding a heat conductive resin composition, which includes heat conductive fillers and a binder resin, into a predetermined shape and curing the heat conductive resin composition to obtain a molded product of the heat conductive resin composition; cutting the molded product into sheets to obtain at least one molded product sheet; and coating a surface of the molded product sheet with an uncured component of the binder resin oozing from a main body of the molded product sheet by pressing a slice surface of the molded product sheet.
 2. The method of manufacturing a heat conductive sheet according to claim 1, wherein the binder resin includes liquid silicone gel as a main ingredient and a curing agent, and a compounding ratio of the curing agent to the main ingredient is as follows: Main ingredient:curing agent=35:65 to 65:35.
 3. The method of manufacturing a heat conductive sheet according to claim 1, wherein the heat conductive fillers comprise carbon fibers, and the heat conductive resin composition is extruded and filled into a hollow die, and the heat conductive resin composition is heat cured, to obtain the molded product in which the carbon fibers are orientated randomly with respect to a direction in which the heat conductive resin composition is extruded.
 4. The method of manufacturing a heat conductive sheet according to claim 1, wherein the molded product sheet is pressed via a spacer into a predetermined thickness.
 5. The method of manufacturing a heat conductive sheet according to claim 3, wherein the molded product sheet is pressed via a spacer into a predetermined thickness.
 6. The method of manufacturing a heat conductive sheet according to claim 1, wherein the at least one molded product sheet comprises a plurality of molded product sheets being disposed adjacent to each other, and the molded product sheets are pressed together to manufacture the heat conductive sheet in which the molded product sheets are integrated.
 7. The method of manufacturing a heat conductive sheet according to claim 3, wherein the at least one molded product sheet comprises a plurality of molded product sheets being disposed adjacent to each other, and the molded product sheets are pressed together to manufacture the heat conductive sheet in which the molded product sheets are integrated.
 8. The method of manufacturing a heat conductive sheet according to claim 4, wherein the at least one molded product sheet comprises a plurality of molded product sheets being disposed adjacent to each other, and the molded product sheets are pressed together to manufacture the heat conductive sheet in which the molded product sheets are integrated.
 9. The method of manufacturing a heat conductive sheet according to claim 5, wherein the at least one molded product sheet comprises a plurality of molded product sheets being disposed adjacent to each other, and the molded product sheets are pressed together to manufacture the heat conductive sheet in which the molded product sheets are integrated.
 10. A heat conductive sheet, comprising: a sheet main body made of a cured heat conductive resin composition, which includes heat conductive fillers and a binder resin, wherein a surface of the sheet main body is coated with an uncured component of the binder resin oozing from the sheet main body.
 11. The heat conductive sheet according to claim 10, wherein the entire surface of the sheet main body is coated with the uncured component of the binder resin oozing from the sheet main body as a result of pressing.
 12. The heat conductive sheet according to claim 10, wherein the heat conductive fillers comprise carbon fibers, and the carbon fibers that are present on the surface of the sheet main body are coated with the uncured component of the binder resin oozing from the sheet main body.
 13. The heat conductive sheet according to claim 10, wherein the sheet main body is obtained by integrating a plurality of molded product sheets, each molded product sheet being made of the cured heat conductive resin composition, which includes the heat conductive fillers and the binder resin.
 14. The heat conductive sheet according to claim 12, wherein the sheet main body is obtained by integrating a plurality of molded product sheets, each molded product sheet being made of the cured heat conductive resin composition, which includes the heat conductive fillers and the binder resin.
 15. The heat conductive sheet that is manufactured by the method according to claim
 1. 16. A heat dissipation member, comprising: a heat spreader configured to dissipate heat generated by an electronic element; and a heat conductive sheet disposed on the heat spreader and sandwiched between the heat spreader and the electronic element, wherein the heat conductive sheet includes a sheet main body made of a cured heat conductive resin composition, which includes heat conductive fillers and a binder resin, and an entire surface of the sheet main body is coated with an uncured component of the binder resin oozing from the sheet main body.
 17. The method of manufacturing a heat conductive sheet according to claim 2, wherein the molded product sheet is pressed via a spacer into a predetermined thickness.
 18. The method of manufacturing a heat conductive sheet according to claim 2, wherein the at least one molded product sheet comprises a plurality of molded product sheets being disposed adjacent to each other, and the molded product sheets are pressed together to manufacture the heat conductive sheet in which the molded product sheets are integrated. 